Mycological biopolymers grown in void space tooling

ABSTRACT

A mycological biopolymer product consisting entirely of fungal mycelium is made by inoculating a nutritive substrate with a selected fungus in a sealed environment except for a void space, which space is subsequently filled with a network of undifferentiated fungal mycelium. The environmental conditions for producing the mycological biopolymer product, i.e. a high carbon dioxide (CO2) content (from 5% to 7% by volume) and an elevated temperature (from 85° F. to 95° F.), prevent full differentiation of the fungus into a mushroom. There are no stipe, cap, or spores produced. The biopolymer product grows into the void space of the tool, filling the space with an undifferentiated mycelium chitin-polymer, which is subsequently extracted from the substrate and dried.

INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 14/336,455,filed Jul. 21, 2014, entitled MYCOLOGICAL BIOPOLYMERS GROWN IN VOID SPACE TOOLING, which claims the benefit of U.S. Provisional Patent Application No. 61/860,394 filed Jul. 31, 2013, entitled MYCOLOGICAL BIOPOLYMERS GROWN IN VOID SPACE TOOLING, the disclosures of which are incorporated herein by reference in their entirety. Any and all applications for which a foreign or domestic priority claims is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 C.F.C. § 1.57.

BACKGROUND OF THE INVENTION Field of the Invention

This invention relates to mycological biopolymers grown in void space tooling.

Description of the Related Art

As is known from U.S. Ser. No. 12/001,556, filed Dec. 12, 2007, a self-supporting composite material may be made of a substrate of discrete particles and a network of interconnected mycelia cells extending through and around the discrete particles and bonding the discrete particles together. In general, these composite materials may be classified as mycological biocomposites comprised of lignocellulosic waste materials, fungal cellular tissue, and potentially supplemental nutrients (minerals, vitamins, and the like).

As is also known from pending U.S. patent application Ser. No. 13/411,877, there is a potential to introduce variations in functionalization while maintaining continuous, porous, or structural hyphal morphology in the event that mycelial tissue is grown into a biocomposite, or combined with lignocellulosic waste and/or combinations of other additives.

SUMMARY OF THE INVENTION

It is an object of the invention to provide a mycological biopolymer material for use in making functional products.

It is another object of the invention to provide simple economical techniques for making mycological biopolymer products.

Briefly, the invention provides a material composed entirely of fungal mycelium, herein referred to as “mycological biopolymer.” Mycological biopolymer has a wide range of material applications, based on the growth and processing of material, which include: structural composite cores, athletic workout mats, shoe soles, and the like.

Unlike mycological biocomposites which are comprised of lignocellulosic waste materials, fungal cellular tissue, and potentially supplemental nutrients (minerals, vitamins, and the like), the mycological biopolymer product consists entirely of fungal mycelium. This mycological biopolymer is home compo stable and is a green alternative to products currently used in the industry, such as: ethylene vinyl acetate foams, polyvinyl chloride plastics, polyurethane foams, and the like. This technology may be used for applications currently employing non-renewable to slow-renewable substrates, which require high-energy inputs, multiple costly ingredients, and non-desirable chemical inputs.

The mycological biopolymer provides a low embodied energy, natural, and compostable alternative to conventional expanded foams. This bio-based industrial product is up-cycled from domestic agricultural lignocellulosic waste, sourced regionally (within 500 miles) , and promotes the growth of the agriculture industry while reducing cumulative usage of fossil fuels. The biopolymer negates the need for conventional, energy-intensive, chemical extraction, refinement, and synthesis of expanded foams. The product of the invention literally grows itself, using little to no energy to produce the biopolymer apart from the energy used in sterilization, growth conditions, and drying.

The invention also provides a process for making the mycological biopolymer which uses a tooling paradigm that exploits the tendency of the fungus to grow toward a lower carbon dioxide content environment. The tools are designed to regulate the area in which the colonized material is in contact with regulated environmental conditions.

In one embodiment, the tooling includes tool to contain a nutritive substrate inoculated with the selected fungus and a lid on the tool to contain the nutritive substrate inoculated with the selected fungus in a sealed environment, except for a void space, which space is subsequently filled with a network of undifferentiated fungal mycelium in accordance with the invention.

The environmental conditions for producing the mycological biopolymer product, i.e. a high carbon dioxide (CO₂) content (from 5% to 7% by volume) and an elevated temperature (from 85° F. to 95° F.), prevent full differentiation of the fungus into a mushroom. There are no stipe, cap, or spores produced. The elevated temperature accelerates tissue production. The biopolymer product grows into the void space of the tool, filling the space with an undifferentiated mycelium chitin-polymer, which is subsequently extracted from the substrate and dried.

In one embodiment, in a first step, a tool is provided that defines a cavity and a lid is provided which seals at the edges of the tool and has an opening which creates a void space. For example, the tool is made of polycarbonate and is 21 inches by 13 inches by 2 inches with a completely open top. The lid is made of polyethylene plastic and seals along the top edge of the tool. The center of the lid has a 12 inch by 6 inch opening, which is surrounded by 1 inch high walls.

Next, the cavity of the tool is packed with nutritive substrate and spawn (i.e. a selected fungus) and the substrate is flattened across the top of the tool using a smoothing plate.

Thereafter, the lid is placed on the tool, sealing the top edges of the tool and providing an enclosed space containing the substrate and spawn as well as a void space within the lid. This combination of tool and lid provides only one outlet open to the controlled environmental conditions.

The fungus is then allowed to grow mycelium within the cavity and the mycelium respirates within the tool thereby producing carbon dioxide while colonizing the nutritive substrate.

During this time, the produced carbon dioxide is trapped in the tool and diffuses out of the outlet in the lid to create a gradient of carbon dioxide while the mycelia, searching for a more habitable environment, is allowed to grow along the gradient out of the cavity of the tool and to fill the void space within the lid without producing a stipe, cap or spore therein and to produce an entirely mycelium biopolymer.

The mycological biopolymer product can be used as a composite core to replace balsa, honeycomb, synthetic foams and aluminum. This technology offers several energy reducing benefits because the product grows itself in a matter of days. Additionally, the product can be grown through the reinforcement layer of traditional composites. This reinforcement layer can be composed of any material that mycelium can grow through (pore size larger than 1 microns). These layers can be suspended in the void space created by the tooling that is filled with biopolymer during incubation. These reinforcement layers are then incorporated into the biopolymer producing a pre-form of the composite core and reinforcement layers.

A laminate can be bound to the pre-form of composite core and reinforcement layers by extracting the pre-form from the substrate, and incubating the pre-form against the laminate material. This eliminates the need for the energy intensive process of setting and curing the layers of a traditional composite to adhere them, which typically involves autoclaving the materials. This also reduces the use of toxic adhesives, time, and labor needed to produce composites.

Finally, the biopolymer is compostable, so at the end of life, the core material can be degraded away from any synthetic reinforcement layer or laminates, and the synthetic reinforcement layer or laminates can be recycled.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other objects of the invention will become more apparent from the following description taken in conjunction with the drawings wherein:

FIG. 1 illustrates a flow diagram of a general process for growing biopolymer in accordance with the invention;

FIG. 2 illustrates a flow diagram of a process for producing biopolymer as a composite core replacement in accordance with the invention;

FIG. 3 illustrates a flow diagram of a process for the production of a composite core;

FIG. 4A illustrates a perspective view of a tool for growing biopolymer in accordance with the invention;

FIG. 4B illustrates a perspective view of a lid for placement on the tool of FIG. 4A;

FIG. 4C illustrates an exploded view of the tool and lid of FIGS. 4A and 4B when in place;

FIG. 4D illustrates a perspective view of the tool and lid of FIGS. 4A and 4B when in place;

FIG. 5 illustrates the placement of reinforcement layers for incorporation into the final composite;

FIG. 6A illustrates a vertically disposed tool for growing biopolymer in accordance with the invention;

FIG. 6B illustrates a horizontally disposed tool for growing biopolymer in accordance with the invention;

FIG. 7 schematically illustrates a hydroponic tool for growing biopolymer in accordance with the invention;

FIG. 8 illustrates a modified hydroponic tool for growing biopolymer in accordance with the invention; and

FIG. 9 illustrates a further hydroponic tool for growing biopolymer in accordance with the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 1, the process for making a mycological biopolymer product in accordance with the invention entails a first step A of substrate preparation which includes:

-   A.1—mixing of nutrient components and water -   A.2—sterilization -   A.3—inoculation of substrate with mushroom tissue -   A.4—mixing of all components

The next step B is to obtain a packing tool and includes:

-   B.1—filling the tool with the prepared substrate -   B.2—leveling the surface of the substrate with a smoothing plate -   B.3—placing a lid on the tool and sealing the tool while forming a     void space

The next step C involves the incubation and growth of the mycelium and includes:

-   C.1—precolonization for up to four days to allow mycelium to access     nutrients prior to biopolymer growth -   C.2—incubation at high temperatures and carbon dioxide     concentrations to induce biopolymer growth wherein the environmental     temperature is from 85° F. to 95° F. and carbon dioxide constitutes     from 3% to 7% of the environment within the void space.

The last step D involves drying of the produced biopolymer product, for example by:

-   D.1—convection -   D.2—conduction -   D.3—microwave -   D.4—freeze drying

FIG. 1 graphically illustrates the general process for growing biopolymer. All following flow charts are an expansion of this general process, and will begin at step B packing tools. Substrate preparation (step A) is the same for all following applications.

Referring to FIG. 4A, by way of example, a tool 10 for growing biopolymer is of rectangular shape and defines a rectangular cavity 11 for receiving a substrate (not shown). The tool is made of polycarbonate and is 21 inches by 13 inches by 2 inches with a completely open top.

Referring to FIG. 4B, a lid 12 for sealing the tool 10 is also of rectangular shape to sit on the periphery of the tool in sealed relation (see FIGS. 4C and 4D) and has an opening 13 which creates a void space. For example, The lid 12 is made of polyethylene plastic and seals along the top edge of the tool 10. The center of the lid 12 has a 12 inch by 6 inch opening, which is surrounded by 1 inch high walls 14 to define the void space.

Referring to FIG. 2, the process for producing biopolymer as an expanded foam replacement includes a first step of substrate preparation, as above, followed by a step B of packing the substrate into a tool that includes:

-   B.1—filling the tool with the prepared substrate, or -   B.2—suspending mats in the tool space to be filled with substrate in     order to increase tensile strength in the finished product -   B.3—placing a lid on the tool and sealing the tool while forming a     void space

The next step C involves the incubation and growth of the mycelium and specifically includes:

-   C.1—incubation at high temperatures and carbon dioxide     concentrations For 5 to 14 days to induce biopolymer growth -   C.2—the environmental conditions may be altered after the material     has reached a final volume in order to increase cross-linking and     strength and/or -   C.3—various morphological modifiers may be sprayed onto the surface     of the biopolymer or misted in the environment to alter the     morphology of the mycelia, for example using hormones, forskolin,     calcium, calcium blockers (cobalt chloride)

The next step D involves:

-   D.1—extracting the biopolymer material from the space within the     lid, for example, using a blade to separate the biopolymer material     from the substrate

These steps are followed by:

-   E.1—compressing the biopolymer material to the desired dimensions     and density or 3D shape and incubated for an additional 0 to 72     hours to increase strength and density -   F.1—material is freeze dried -   G.1—dried material is sanded, cut or milled to shape

Referring to FIG. 3, the process for producing biopolymer as a composite core material includes a first step of substrate preparation, as above, followed by a step B of packing the substrate into a tool that includes:

-   B.1—filling the tool with the prepared substrate, or -   B.2—suspending reinforcement layers of woven or non-woven mats in     the tool space to be filled with substrate so that as the biopolymer     grows within the tool space, the reinforcement layers will be     incorporated into the core material being produced

The next step C involves the incubation and growth of the mycelium and specifically includes:

-   C.1—incubation at high temperatures and carbon dioxide     concentrations for 5 to 14 days to induce biopolymer growth -   C.2—the environmental conditions may be altered after the material     has reached a final volume in order to increase cross-linking and     strength and/or -   C.3—various morphological modifiers may be sprayed onto the surface     of the biopolymer or misted in the environment to alter the     morphology of the mycelia, for example using hormones, forskolin,     calcium, calcium blockers (cobalt chloride) and/or -   C.4—the biopolymer may be cut to shape and compressed vertically to     increase strength and density

The next step D involves:

-   D.1—extracting the biopolymer material from the nutritious substrate     base in the tool, for example, using a blade

These steps are followed by:

-   E.1—compressing the biopolymer material to the desired dimensions     and density or 3D shape and incubated for an additional 12 to 72     hours to increase strength and density, and/or -   E.2—the biopolymer may be incubated while being sandwiched by a     laminate material for an additional 0 to 72 hours with the growth     allowing for adhesion to the laminate material -   F.1—the biopolymer material is then dried and/or compressed by any     of the following methods or combinations thereof: -   conductively compressed -   conductive dried -   convective dried -   freeze dried -   microwave dried

Referring to FIG. 5, the reinforcement mats 15 may be positioned horizontally, as viewed, to extend transversely across the biopolymer 16 and above the nutrient substrate 17 in order to be incorporated into the final composite.

Referring to FIGS. 6A and 68, wherein like reference characters indicate like parts as above, the tooling for the growth of biopolymer 16 may be arranged for vertical growth or horizontal growth.

The orientation of growth, i.e. when the product is directed to grow either vertically (perpendicular from the substrate) or horizontally (laterally from the substrate) changes the morphology of the fungus and thus the mechanical characteristics of the product.

The tooling shown in FIGS. 6A and 68 are provided specifically to produce either vertical or horizontal mycelium by placing the void space (13—see FIG. 4D) to be filled with biopolymer on top of the substrate or to the side of the substrate. The tooling to produce vertical mycelium was provided with the shortest distance from the substrate surface, where carbon dioxide is produced, to the opening of the void space tool (not shown), allowing for fast diffusion, creating a homogenous environment (FIG. 6A). The horizontal tool has a much longer distance from the substrate surface to the opening, allowing for the production of a greater carbon dioxide gradient (FIG. 68). Horizontal mycelium is produced when there is a differential in the atmosphere, causing the mycelium to grow along the plastic tooling towards an oxygen source.

These two types of biopolymer have two distinct morphologies; vertical mycelium growing upward from the surface of the substrate, and horizontal mycelium growing outwards along the plastic tooling away from the substrate.

Vertical mycelium (FIGS. 6A) was shown to be composed of a highly integrated and un-oriented structure. While the structure making up the horizontal mycelium (FIGS. 68), is extremely aligned with a highly oriented network. These morphological differences have a great effect on the material properties of biopolymer produced. The horizontally grown biopolymer has greater tensile strength in the direction of growth, similar to the grain of balsa wood. The vertically grown biopolymer has the same strength characteristics in all directions, which is a benefit of this material because the material can be used in any orientation.

In order to increase the overall consistency of the material, the tools can be designed so that the open surface of substrate (exposed to the void space to be filled with biopolymer) has a more homogenous environment. The walls (14—see FIG. 4D) at the edge of the void space create a microenvironment that is different from that at the center of the void space. The environment regulates the fungal tissue physiology and morphology, affecting the final material characteristics. Reducing the wall height of the void space can increase the consistency of the environment, because the reduction in wall height minimizes the microenvironment effect of gasses settling within the walls of the void space. The wall height can be increased incrementally as the biopolymer fills the space to create larger materials. Additionally, a grid can be placed on the surface of the substrate, in the void space, in order create smaller pockets of microenvironments. This structure provides additional vertical surface area to promote consistent growth that is more evenly cross-linked. Prior to the completion of the growth the grid can be removed to permit the mycelium to conjoin with the adjacent tissues. Further, the grid can provide partitions that are designed to impart flexibility once the structure in removed and the mycological biopolymer is dried.

Nutrient and Water addition

In order to scale this technology, it would be economical to develop a hydroponic system from which to grow biopolymer. This system would use an inorganic matrix that could be colonized by mycelium while it is fed by liquid nutrients, as shown in FIG. 7. This type of system would abolish the use of the organic substrate that is used for only one cycle of biopolymer growth, minimizing the waste that is generated. The system would allow for the use of waste liquid nutrients, such as spent brewers yeast. The use of liquid nutrients would increase efficiency of the system because the colonized inorganic matrix could be used for multiple cycles of biopolymer production, with nutrients continuously being pumped in while waste is pumped out.

Referring to FIG. 7, wherein like reference characters indicate like parts as above, use may be made of a hydroponic tool to produce the mycological biopolymer. As indicated, an inorganic matrix 17 is colonized with mycelium within a tool 1O′ of vertically disposed cylindrical shape with a lid 12′, as above, and liquid nutrients are pumped through the matrix 17 via an inlet 18 and an outlet 19 continuously feeding the mycelium and removing waste. The relative humidity, temperature, carbon dioxide and oxygen levels are manipulated on the surface of the matrix 17 allowing for the production of the mycological biopolymer.

Referring to FIG. 8, wherein like reference characters indicate like parts as above, the tool 10″ is disposed horizontally with an inlet 18′ and outlet 19′ for a flow through of liquid nutrients.

Referring to FIG. 9, wherein like reference characters indicate like parts as above, the tool 20 is vertically disposed with one chamber 21 to contain the inoculated substrate 17 and a second parallel chamber 22 to receive the mycological biopolymer 16. In the embodiment, the liquid nutrient may flow downwardly through the substrate 17 while the environmental air flows upwardly through the second chamber 22.

Regulating Morphology

There are many ways to regulate the morphology and differentiation of the fungal tissue, and these techniques can be used to control the final material characteristics of the biopolymer material. Competitive species can be used to trigger differentiation and fruiting to enhance the efficiency of the material production system. Fungal hormones, such as 10-oxo-trans-8-decenoic acid (ODA), can be used in this way as well (PPA 61/951,056). Chemical supplements, such as forskolin, can also be added to the substrate, or misted onto the surface of growing biopolymer. Forskolin acts by activating that production of cAMP in the cell that triggers a signaling cascade, which increases the branching, or cross-linking, of the material. Finally, growing the material in an electric field will increase the alignment of hyphae, increasing the tensile strength in that direction. All of the techniques can be used to increase the consistency and efficiency of the material as well as the strength characteristics. 

1-15. (canceled)
 16. An apparatus for growing a mycological biopolymer, comprising: a tool defining a cavity and an opening into the cavity; a nutritive substrate and a fungus, the nutritive substrate inoculated with fungal mycelia and positioned within the cavity, wherein growth of the mycelia within the cavity produces carbon dioxide; a lid configured to fit on the tool to seal the cavity, the lid having only one lid outlet therein defining a void space open to fresh air, wherein the lid outlet is configured to allow the carbon dioxide to diffuse out of the tool to create a gradient of carbon dioxide, and wherein the void space is configured to provide the mycelia with space to grow along the gradient without producing a stipe, cap or spore therein.
 17. The apparatus of claim 16, wherein the void space is configured to create an environment constituting from 3% to 7% carbon dioxide.
 18. The apparatus of claim 17, wherein the void space has an environmental temperature from 85° F. to 95° F.
 19. The apparatus of claim 16, wherein the void space is disposed vertically above the substrate.
 20. The apparatus of claim 16, wherein the void space is disposed horizontally beside the substrate.
 21. The apparatus of claim 16, wherein the tool further comprises a tool inlet and a tool outlet, wherein the tool inlet is configured to provide a liquid nutrient into the cavity for feeding the mycelia, and the tool outlet is configured to remove waste from the cavity.
 22. An apparatus for growing a mycological biopolymer, comprising: a nutritive substrate and a fungus; a tool filled with the nutritive substance and the fungus; a lid positioned on the tool to cover and seal the nutritive substance and the fungus within the tool, the lid having only one lid outlet therein defining a void space open to fresh air, wherein the void space comprises an incubation environment comprising a temperature between 85° F. to 95° F., and carbon dioxide content between 3% to 7%; and a mycological biopolymer within the void space without a stipe, cap or spore.
 23. The apparatus of claim 22, further comprising one or more mats suspended in the void space and incorporated into the mycological biopolymer, for increase tensile strength of the mycological biopolymer.
 24. The apparatus of claim 22, further comprising at least one morphological modifier on a surface of the mycological biopolymer and/or within the incubation environment, the morphological modifier configured to alter the morphology of the mycelia within the mycological polymer.
 25. The apparatus of claim 24, wherein the morphological modifier comprises at least one of a hormone, forskolin, calcium, and a calcium blocker.
 26. A compressed mycological biopolymer comprising the mycological biopolymer of claim 22, wherein the compressed mycological biopolymer is compressed to predetermined dimensions to increase strength and density prior to the step of drying.
 27. The compressed mycological biopolymer of claim 26, wherein the compressed mycological biopolymer comprises a three-dimensional compression in a predetermined shape.
 28. The apparatus of claim 22, further comprising a pair of laminates, with the mycological biopolymer sandwiched between and adhered to the pair of laminates.
 29. An apparatus for growing a mycological biopolymer, comprising: a tool comprising: a pair of vertically disposed chambers comprising a first chamber and a second chamber; and a vertically disposed wall separating the chambers, wherein a plurality of chamber openings extend through the wall to allow the first chamber and the second chamber to communicate with each other; a first inlet configured to provide a liquid nutrient to the first chamber, and pass the through a nutritive substrate and a fungus contained within the first chamber; and a second inlet configured to provide environmental air through the second chamber.
 30. The apparatus of claim 29, wherein the first inlet and the second inlet are configured such that the liquid nutrient and the environmental flow in opposite directions relative to each other.
 31. An apparatus for growing a mycological biopolymer, comprising: a chamber; an inoculated substrate placed into the chamber, the inoculated substrate containing a fungus; mycelium growth from the fungus within the chamber, wherein the chamber comprises carbon dioxide at a chamber carbon dioxide level resulting from respiration of the mycelium growth; a perforated barrier which separates the chamber from an environment, wherein the environment comprises carbon dioxide at an environment carbon dioxide level that is less than the chamber carbon dioxide level, wherein the perforated barrier is configured to allow the carbon dioxide within the chamber to diffuse through the perforated barrier to the environment, and create a carbon dioxide gradient between the chamber and the environment; and a mycological biopolymer extending from the chamber, through the perforated barrier, and into the environment, without a stipe, cap or spore.
 32. The apparatus of claim 31, wherein the environment has a carbon dioxide content of 3% to 7%.
 33. The apparatus of claim 32, wherein the environment has an environmental temperature from 85° F. to 95° F.
 34. The apparatus of claim 31, wherein the environment is disposed vertically above the substrate.
 35. The apparatus of claim 31, wherein the environment is disposed horizontally beside the substrate.
 36. The apparatus of claim 31, wherein the perforated barrier comprises a lid having only one outlet.
 37. The process of claim 31, wherein the perforated barrier comprises a reinforcement layer.
 38. The process of claim 22, wherein the reinforcement layer has a pore size greater than 1 micron.
 39. The process of claim 37, wherein the reinforcement layer is a woven or non-woven mat.
 40. The apparatus of claim 31, further comprising at least one morphological modifier on a surface of the mycological biopolymer and/or within the incubation environment, the morphological modifier configured to alter the morphology of the mycelia within the mycological polymer.
 41. The apparatus of claim 40, wherein the morphological modifier comprises at least one of a hormone, forskolin, calcium, and a calcium blocker. 